PIC MICROCONTROLLER TEMPERATURE CONTROL SYSTEM AN APPLICATION OF THE PIC MICROCONTROLLERS

A TERM PROJECT

Submitted to

Prof. Dr. Doan BRAHM of Near East University

by Hseyin Gney

in partial fulfillment of the requirements for the course COM 528 Advance Microprocessors

in Computer Engineering Department Master Program

Nicosia, Turkish Republic of Northern Cyprus May 04, 2012

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PIC MICROCONTROLLER ABSTRACT This report is about an example of application of PIC Microcontroller systems. The example stated in this report is temperate control system. The PIC Microcontrollers are the single silicon base general purpose microcomputers and this PIC Microcontrollers are used in control applications like temperature control systems, water level etc. The purpose of this report is to provide an overview on PIC Microcontroller based temperature control systems. The report concludes that PIC Microcontrollers are very important and suitable for temperature control systems.

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PIC MICROCONTROLLER TABLE OF CONTENTS ABSTRACT.............................................................................................................................2 TABLE OF CONTENTS.........................................................................................................3 LIST OF FIGURES..................................................................................................................4 LIST OF TABLES...................................................................................................................5 INTRODUCTION....................................................................................................................6 CONCLUSION......................................................................................................................36

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PIC MICROCONTROLLER LIST OF FIGURES

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PIC MICROCONTROLLER LIST OF TABLES

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INTRODUCTION
First of all, a microcontroller is a electronic device that combines several components of a microprocessor system onto a single microchip. In addition, PIC means to "Programmable Interface Controller. PIC microcontrollers are widely used by amateur designers or at enterprise levels. On the other hand, the PIC Microcontrollers are the new technology in the field of electronics control. In other words, a complete electronic computer solution in a embedded microchip. The microcontroller is used as a single chip as a control unit. there are lots of examples in industry. For example, a washing machine, temperature sensor, water level sensor, TV remote control etc. The PIC applications and fields are vey huge I will explain temperature controller system upcoming parts of my report.

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PIC MICROCONTROLLER Description of PIC Microcontrollers

Before getting detailed explanation of PIC microcontrollers, I would like to explain microcontrollers. Microcontroller is a device that combine components of a microcomputer system on a single silicon based microchip. Moreover, main aim of this device is interact electronic devices and human beings by using on-board interfaces. Especially, a microcontroller system has a CPU, Ram, Rom, I/O and some other specialized circuits which are combined in one chip. Despite microprocessors, microcontrollers have all components in chip but in microprocessors all components are connected to CPU externally. PIC microprocessors developed by using Harvard microcontroller architecture which made by Microchip Technology. The name PIC firstly referred to "Peripheral Interface Controller". PIC microcontrollers are popular with both enterprise developers and hobbyists because they have low cost, wide availability, large user groups, collection of application notes, availability of low cost or free development tools, and serial programming (and re-programming with flash memory) capability. Finally, I would like to put advantages and basic components of a microcontroller as follow. The main components are CPU Core, Memory (RAM and ROM) and I/O. The advantages of PIC Microcontroller are small instruction set, RISC architecture, selectable speed, easy entry level in-chip programming, inexpensive etc.

Figure1. Microcontroller's fundamental components Description of Temperature Control Systems

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PIC MICROCONTROLLER The temperature controller described here uses most of the available I/O provided, including analog inputs. The 8k memory should be sufficient for most application programs which might be developed for this hardware. A demonstration program is provided which will exercise the hardware for test purposes, but it will be left to the reader to develop a fully functional application. A temperature controller is required to control a system such as a greenhouse where the temperature must be kept within set limits (050C) by a heating and ventilation system below.

Figure2. Temperature Control System

The unit will be programmed to accept a maximum and minimum temperature, or a set temperature and operating range. The system operates on the average temperature reading from four sensors to give a more accurate representation of the overall temperature in the enclosure. Using more than one temperature sensor also allows the system to tolerate a fault in one sensor, if the application software includes a check to see if one sensor is out of range.

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PIC MICROCONTROLLER The temperature is maintained by a switched heater, switched vent and a fan which can be speedcontrolled. The system should operate as specified in Table 1. The fan is fitted to the heater, so that it can be used for forced heating or cooling, depending on whether the -

Table 1: Temperature Controller Function Table

heater is on. It needs to be connected to a PWM output on the controller if the rate of forced heating and cooling is to be varied. A demonstration system was constructed, where the heater was represented by a pair of lament lamps and the fan by a 5 V CPU fan. The temperature sensors were standard LM35 devices which have a built-in amplifier which outputs 10 mV per C. Figure 2.2 shows the interfacing requirements for the application. The temperature sensor readings can be averaged, or processed with a weighting factor for each, to give a representative value for the

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PIC MICROCONTROLLER measured temperature. A heater is then controlled via a suitable -

Figure 3: Temperature Controller Interfacing

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PIC MICROCONTROLLER interface. A relay can be used if on/off control is sufficient. If proportional control is required, a PWM output would be required. In the hardware design provided here, the heater and vent interfaces are implemented as normally open switched relays, so that an external power supply can be used. The fan output demonstrates the alternative solid state interface, using a general purpose power FET. This would allow proportional control, but the external circuit must be operated at 5 V. For PWM control, the FET output would have to be re-allocated to one of the PWM outputs on the PIC 16F877.

Steps of Temperature Control System I/O Allocation The I/O functions provided by the PIC 16F877 are detailed in Table 2. These were then mapped against the requirements of the application, and the most convenient grouping decided, giving the I/O allocation in Table 3. The interfacing for this application is typical of that required for simple control systems using microcontrollers. Fortunately, this application does not need any analog signal conditioning on the input side, as the temperature sensors can be connected directly to the PIC. Other references on interfacing will cover the range of design techniques needed for the most common sensors and output devices.

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Table 2: 16F877 Pin Functions

Table 3: Temperature Controller I/O Allocation Analog Inputs

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PIC MICROCONTROLLER The four temperature sensors are allocated to four of the eight analog inputs available on the chip. In the demo system, standard sensors with an output of 10 mV per C were used (0C 0 mV). The controller is designed to operate at up to 50C, at which temperature the sensor output is 500 mV. This relatively low voltage is acceptable if the sensors are not connected on long leads, which could pick up electrical noise. For more remote operation, a DC amplifier should be used at the sensor end of the connection to increase the voltage to, say, 5.00 V at 50C. Alternatively, or in addition, screened leads could be used. The inputs are protected by a low pass RC filter; the input impedance at the ADC is high enough for this to have negligible effect on the input voltage. The ADC normally operates at 10-bit resolution, giving output values 01024. It needs reference voltages to set the maximum and minimum values for the input conversion. These can be provided internally as Vdd and Vss (supply values), but Vdd does not give a convenient conversion factor. Therefore, an external reference value is provided from a 2.7V zener diode and potential divider, giving Vref which is adjusted to 2.048 V. This then gives a conversion factor of 2048/1024 2 mV per bit. To simplify the software, and to cover the correct range, only the low eight bits of the ADC result will be used, with a maximum value of 255. At 50C,

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Figure 4: 16F877 Temperature Controller Circuit Diagram

the input will be 500 mV/2 mV 250, giving a resolution of 0.2C per bit. For test purposes, a set of four on-board pots are provided, so that input voltages in this range can be input manually, to check the operation of the software without having to heat and cool the target system. These can be switched in and out as required via a bank of DIP switches. Outputs Two types of output are provided, relay and FET. The relay gives a switched output that is isolated (electrically separated) from the controller. The external circuit operates with a separate supply, so the load (heater in this case) can be powered from a high-voltage supply if necessary. The relay also provides a high off resistance (an air gap). The FET interface, on the other hand, is more reliable, as it is solid state. The problem is that the load has to operate from the same supply as the

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PIC MICROCONTROLLER FET, the 5 V board supply. It also does not provide electrical isolation between the controller and the load, unless an opto-isolator is included between the FET and the MCU. However, the FET can be switched at high frequency, while the relay cannot. The outputs include an on-board LED to indicate their status, in case the state of the outputs cannot be seen or are not connected. Components of Temperature Control System Keypad The 12-button keypad allows the user to input the required temperature and other operating parameters as required by the application program. The target temperature would typically be input as a 2-digit number. It may also be desirable to input upper and lower limits, alarm levels and so on. These should be displayed as they are entered, to ensure that the correct figures are stored. The keypad is simply a set of switches connected in a row and column arrangement and accessed by a scanning routine. If the row inputs (A, B, C, D) are all set high initially, and no button is pressed, all the column outputs (1, 2, 3) will be high (pulled up to 5 V). If a 0 is output on each row in turn, and a button pressed, that 0 will appear at the column output, and can be read in to the PIC. The combination of active row and column identifies the key. Display A seven-segment display is used as it is relatively easy to drive, compared with a liquid crystal display, and is self-illuminating. A code to illuminate the segments to display digits 09 is looked up in a program data table. In this case, two digits are required, but they can both be operated from the same set of outputs by multiplexing. The digits are switched on alternately via Q1 and Q2; because they are switched too fast for the eye to perceive, they appear to be on at the same time, albeit at reduced brightness. Other Circuit Elements

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PIC MICROCONTROLLER A buzzer is fitted to provide an audible alarm output. This can be used to signal system failure, temperature too low for too long and so on. Audible feedback from keystrokes is also desirable. A 4 MHz clock is used to give a convenient instruction execution time, although no timing-critical operations are required. In the context of this circuit, cost saving on clock components would be in significant. A manual reset is provided, so that the program can be restarted without powering down. This will be useful for testing as well as in normal operation. In-circuit programming and debugging are provided for via the ICD connector. The ICD module must be connected between the host PC and the application board. MPLAB IDE can then be used for testing the program in software initially, and then finally in ICD mode.

Hardware Development of Temperature Control System The circuit was developed using Labcenter ISIS schematic capture software, which provides interactive components for circuit testing, and integrated software and hardware testing. When the circuit had been tested by interactive simulation, a stripboard implementation was devised (Fig. 8.4). A demo target system was then constructed, comprising two lament lamps as the heaters, operating from a high current 5 V supply, controlled by the relay output on the application board. A 5 V CPU fan was tted as the cooling element, and the temperature sensors were arranged symmetrically inside the enclosure. The wiring of the target hardware is shown in Fig. 8.5. Note that there was a sensor output on the fan which could be used to monitor the actual fan speed, if a suitable interface were designed to convert the fan sensor pulse to TTL levels. The vent was not physically implemented at this stage. The photo of the prototype system (Fig. 8.6) shows the simulator at the right of the picture, with the ICD module (enclosed in ABS box), which is connected to ICD input of the TEMPCON board. 5V power supplies and a host PC would

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PIC MICROCONTROLLER complete the system. When nal hardware testing was completed, an application board was created using Lab center ARES PCB layout software, shown in Fig. 8.7. This incorporated an on-board 5 V supply for operation from a mains adapter.

Temperature Controller Test Program Program 8.1 was written to exercise the hardware and to help get the reader started in developing applications for the TEMPCON hardware. The program will read in the analog inputs and display the raw data on the displays. An apparently random pattern results, which changes if the analog

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PIC MICROCONTROLLER inputs (test pots) are varied, indicating that the hardware input and display interfaces are

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Figure 5: Strip board Layout for TEMPCON Board working. Pressing a key on the keypad will select an analog input for display; key 1 for input 1, and so on to 4, then repeating for keys 58. Key 9 will enable the buzzer test, while *, 0 and # will operate the heater, fan and vent, respectively. A full header has been included with as much information as possible; details of target system, program description, register initialization, port allocation and so on. The ports and analog control registers have been initialized using bank selection, as recommended. Computer Engineering Department, Near East University 19

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Figure 6: Greenhouse Simulator Wiring

Figure 7: TEMPCON System: (a) Strip board Version of Temperature Controller Board

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PIC MICROCONTROLLER

Figure 8: Temperature Controller System with ICD Module and Dummy Load

Figure 9: Temperature Controller Board

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PIC MICROCONTROLLER Source Code of Temperature Control System ;******************************************************************* ; Source File: CON0.ASM ; Design & Code: M Bates ; Date: 29-6-02 ; Version: 1.0 ; Customer: HCAT ; ; Target Hardware: 16F877 Controller Board (TEMPCON Board) ; Design & Layout: M Bates ; ISIS Design File: CON0.DSN ; Layout: Stripboard prototype ; ; Development System: MPLAB ICD Evaluation kit ; MPLAB IDE Ver 5.30.00 ; Assembler: PICSTART Plus 2.40.00 ; ;******************************************************************* ; ; Test program for PIC877 Controller Board using ICD system ; Use with ISIS CON0.DSN for simulation testing ; ; Circuit description:

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PIC MICROCONTROLLER ; PIC 16F877 ash microcontroller gets 4 analogue inputs from temp ; sensors (or test input pots) to control Heater, Vent and Fan in a ; target system such as a greenhouse. Target temp will be set up ; using keypad input and displayed on 2-digit multiplexed LED display. ; Test program: ; Checks all inputs and outputs for correct hardware operation. ; -Press keypad buttons 1-4 to display raw data from input pots ; -Buttons 5-8 ditto ; -Button 9 to sound buzzer ; -Button * to operate HEATER output ; -Button 0 to operate VENT output ; -Button # to operate FAN output ; ; PROGRAMMING OPTIONS ********************************************** ; ; When programming PIC 16F877 in ICD mode, select: ; ; XT clock mode (4MHz, 1us per instruction) ; Power-up timer enabled ; Watchdog timer disabled ; Code Protection off Program 8.1: Test Program for TEMPCON Board ;

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PIC MICROCONTROLLER ; I/O ALLOCATION *************************************************** ; ; INPUTS........................................................... ; ; Analogue temp sensors AN0 - AN3 (0 5V) ; Keypad column detect RD0 - RD2 = 0 ; OUTPUTS........................................................... ; ; Buzzer RB0 = toggle ; Keypad row select RD3 RD6 = 0 ; 7-segment display Select lo digit RB1 = 1 ; Select hi digit RB2 = 1 ; Segments RC1 RC7 = 0 ; Relay interfaces Heater RE0 = 1 ; Vent RE1 = 1 ; FET interface Fan RE2 = 1 ; ; PORT DATA DIRECTION CODES REQUIRED .............................. ; ; TRISA = 11111111 ; TRISB = 11111000 ; TRISC = 00000000 ; TRISD = 00000111

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PIC MICROCONTROLLER ; TRISE = 00000000 ; ; RB3, RB6, RB7 reserved for ICD operation ; ; ADC SETUP ******************************************************** ; ; ADCON0 Bits 76 01 = A/Dclock = f/8) ; Bits 543 Channel Select (AN0 AN7) ; Bit 2 Go = 1 / Done = 0 ; Bit 0 A/D module enable = 1 ; ; ADCON0 = 01xxx001 depending on channel required ; ; ADCON1 Bit 7 0 = left justify result in ADRESH/ADRESL ; Bits 3210 0010 = RA0-RA5 analogue, RE0-RE2 digital ; ; ADCON1 = 00000010 ; ASSEMBLER DIRECTIVES ******************************************** ; ; Create list le and select processor: list p = 16f877 Program 8.1: Continued

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PIC MICROCONTROLLER ; ; Include le containing register labels: include "p16f877.inc" ; count EQU 020 ; assign GPR1 for counter ; ; Set origin at address 000: org 0x000 ; ; START PROGRAM *************************************************** nop ; No op. required at 000 for ICD mode ; Initialise control registers ..................................... banksel TRISA ; Select DDR resgister bank 1 movlw b11111000 ; Setup buzzer and display digit ; select.. movwf TRISB ; ..as outputs clrf TRISC ; Setup 7-segment driver port as outputs movlw b00000111 ; Setup keyboard port for.. movwf TRISD ; .. row outputs and column inputs clrf TRISE ; Setup relay port as outputs ; Setup ADC ....................................................... banksel ADCON1 ; Select register bank 1 movlw b00000010 ; Set A/D mode left justify,4 channels

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PIC MICROCONTROLLER movwf ADCON1 ; and write A/D control word banksel ADCON0 ; Select register bank 0 movlw b01000001 ; Set A/D frequency Fosc/8, select AN0 movwf ADCON0 ; and write A/D control word ; Initialise outputs ....... ....................................... banksel PORTA ; select port data register bank 0 clrf PORTE ; switch off all outputs goto start ; jump over subroutines to main loop ; Subroutine to wait about 0.8 ms .................................. del8 clrf count ; Load time delay of 256 3=768 us again decfsz count ; Decrement and test counter goto again ; until zero return ; ; Subroutine to get analogue input ................................. ; Wait 20us ADC aquisition settling time .. Program 8.1: Continued

getAD movlw 007 ; Load time delay of 7 3=21 us movwf count ; Load counter down decfsz count ; Decrement and test counter goto down ; until zero (3us per loop) ; Get analogue input .. bsf ADCON0, GO ; Start A/D conversion

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PIC MICROCONTROLLER wait btfsc ADCON0,GO ; Wait for conversion to complete goto wait ; by testing GO/DONE bit return ; from subroutine with result in ; ADRESH ; Subroutines to process keys ................................... proc1 movlw b01000001 ; Select analogue channel 1 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key proc2 movlw b01001001 ; Select analogue channel 2 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key proc3 movlw b01010001 ; Select analogue channel 3 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key proc4 movlw b01011001 ; Select analogue channel 4 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key proc5 movlw b01000001 ; Select analogue channel 1 movwf ADCON0 ; and

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PIC MICROCONTROLLER call getAD ; and get analogue input return ; for next key proc6 movlw b01001001 ; Select analogue channel 2 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key proc7 movlw b01010001 ; Select analogue channel 3 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key Program 8.1: Continued proc8 movlw b01011001 ; Select analogue channel 4 movwf ADCON0 ; and call getAD ; and get analogue input return ; for next key proc9 bsf PORTB,0 ; Toggle buzzer on call del8 ; delay about 0.8ms bcf PORTB,0 ; Toggle buzzer off call del8 ; delay about 0.8ms return ; for next key procs bsf PORTE,0 ; switch on heater output return ; proc0 bsf PORTE,1 ; switch on vent output

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PIC MICROCONTROLLER return ; proch bsf PORTE,2 ; switch on fan output return ; ; Routine to scan keyboard .................................... scan movlw 0FF ; Deselect... movwf PORTD ; ...all rows on keypad ; scan row A of keypad .......... bcf PORTD,3 ; select row A of keypad btfsc PORTD,0 ; test key 1 goto key2 ; next if not pressed call proc1 ; process key 1 key2 btfsc PORTD,1 ; test key 2 goto key3 ; next if not pressed call proc2 ; process key 2 key3 btfsc PORTD,2 ; test key 2 goto key4 ; next if not pressed all proc3 ; process key 3 ; scan row B of keypad .......... key4 bsf PORTD,3 ; deselect row A bcf PORTD,4 ; select row B btfsc PORTD,0 ; test key 4 goto key5 ; next if not pressed call proc4 ; process key 4

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PIC MICROCONTROLLER Program 8.1: Continued key5 btfsc PORTD,1 ; test key 5 goto key6 ; next if not pressed call proc5 ; process key 5 key6 btfsc PORTD,2 ; test key 6 goto key7 ; next if not pressed call proc6 ; process key 6 ; scan row C of keypad ......... key7 bsf PORTD,4 ; deselect row B bcf PORTD,5 ; select row C btfsc PORTD,0 ; test key 4 goto key8 ; next if not pressed call proc7 ; process key 4 key8 btfsc PORTD,1 ; test key 5 goto key9 ; next if not pressed call proc8 ; process key 2 key9 btfsc PORTD,2 ; test key 2 goto keys ; next if not pressed call proc9 ; process key 3 ; scan row D of keypad ...... keys bsf PORTD,5 ; deselect row C bcf PORTD,6 ; select row D btfsc PORTD,0 ; test key *

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PIC MICROCONTROLLER goto key0 ; next if not pressed call procs ; process key * key0 btfsc PORTD,1 ; test key 0 goto keyh ; next if not pressed call proc0 ; process key 0 keyh btfsc PORTD,2 ; test key # goto done ; next if not pressed call proch ; process key # Program 8.1: Continued ; all done .................. done return ; to main loop ; Main program *************************************************** start bcf PORTB,2 ; switch off high digit of display bsf PORTB,1 ; and switch on low digit call scan ; and read keypad movf ADRESH,W ; move ADC result movwf PORTC ; to display bcf PORTB,1 ; switch off low digit of display bsf PORTB,2 ; and switch on high digit call scan ; and read keypad movf ADRESH,W ; move ADC result movwf PORTC ; to display goto start ; repeat main loop

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PIC MICROCONTROLLER END ; of source code .................. Program 8.1: Continued

The routine to read in an analog input is based on the model routine provided in the datasheet, where a delay of about 20 s is included to ensure that the input has had time to settle, in case the input is changing rapidly. The conversion is then started by setting the GO bit in the ADC control register, and then waiting for it to be cleared by the ADC to indicate that the conversion is complete. In this program, only 8 of the 10 bits of the ADC result are used, so the result is left justi ed to place the most signi cant 8 bits in the ADRESH register for output to the display. This allows the full range of the input (02.048 V) to be checked. In a working program, the analog input value would be converted into a 2-digit decimal value for the display. Using the conversion scaling calculated above, a temperature of 50C would give a result of 250 (in binary) in ADRESL, with the result right justi ed. Only a quarter of the full ADC range is then being used. This result can then be converted into the corresponding display digits 5 and 0, and so on down to zero. The keyboard-scanning routine uses a simple method to check if each key in each row has been pressed, calling the required action if it has. A more elegant and compact keyboardscanning method is possible when reading in numerical values. A full working program would allow the user to enter the maximum and minimum values for the target temperature, and then go into run mode, where the temperature would be controlled within the set range by operation of the heater, vent and fan. Pseudocode for the application software is shown in Program 8.2.

TEMPCON

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PIC MICROCONTROLLER Initialize Ports Port A = Temp sensor inputs (4) Port B = Display digit select (2), ICP/D (3) Port C = Display segments (7) Port D = Keypad (4 outputs, 3 inputs) Port E = Heater, Vent, Fan outputs ADC Left justify, 4 channels ADC frequency Fosc/8, select input AN0 GetMaxMin Scan keyboard Store & display rst digit of maxtemp Scan keyboard Store & display second digit of maxtemp Convert to byte MaxTemp (0-200) Scan keyboard Store & display rst digit of mintemp Scan keyboard Store & display second digit of mintemp Convert to byte MinTemp Cycle Read tempsensor1

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PIC MICROCONTROLLER Read tempsensor2 Read tempsensor3 Read tempsensor4 IF sensor out of range replace with previous value Calculate AverageTemp Display AverageTemp MSD = AverageTemp/10 Get 7-seg code & display MSD LSD = Remainder Get 7-seg code & display LSD IF AverageTemp > Mintemp switch heater OFF ELSE switch heater ON Program 8.2: Pseudocode for TEMPCON Control Software IF AverageTemp > Maxtemp switch vent ON ELSE switch vent OFF IF AverageTemp > Maxtemp + 4 switch fan ON ELSE switch fan OFF GOTO Cycle

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CONCLUSION

In this report, I tried to introduce an application of PIC microcontrollers which is Temperature Control System and explain some important points of Microcontrollers, PIC Microcontrollers, and Temperature Control System. I have shown that Temperature Control system can be easily developed on PIC Microcontrollers. PIC Microcontrollers are very useful, cheap and suitable for this kind of applications. I have described purposes of designing and construction PIC Microcontroller system and Temperature Control Systems. In addition, I emphasized that different PIC systems can be developed. Moreover, I have explained that it is suitable for amateurs and professionals to develop such systems. These explanations show that PIC microcontrollers are very useful and can be developed by everybody. It is therefore very important to know PIC microcontroller technology because it is be a part of our daily lives.

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REFERENCES

Lucio Di Jasio, Tim Wilmshurst, Dogan Ibrahim, John Morton, Martin Bates, Jack Smith, D.W. Smith, and Chuck Hellebuyck. PIC Microcontrollers: Know it All: ISBN: 978-0-7506-86150.

Wikipedia. PIC Microcontrollers, Retrieved at January 2012, from the world wide web: http://en.wikipedia.org/wiki/PIC12.

Pic Tutorials. What is Microcontroller, Retrieved at January 2012, from the world wide web: http://www.pictutorials.com/what_is_microcontroller.htm.

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